Head removal HONDA CIVIC 2003 7.G User Guide

Gylinder Head
Auto-Tensioner Removal/l nstallation
3. Align the holes on the lock (A) and the auto-
tensioner (B), then insert a 1.5 mm (0.06 in.)
diameter pin (C) into the holes. Turn the crankshaft
clockwise to secure the oin.
4. Remove the auto-tensioner.
6-20
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(cont'dl
Installation:
1. Install the auto-tensioner.
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6x1.0mm12 N.m {1.2 kgt.m, 8.7 lbt.tt)
Remove the pin from the auto-tensioner.
a\

Gylinder Head
Cylinder Head Cover Removal
1. Remove the intake manifold cover.
2. Remove the four ignition coils (see page 4-'18).
3. Remove the dipstick (A) and breather hose (B).
6-22
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4, Remove the cylinder head cover
V:t :;t 1
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Gylinder Head Removal
NOTE:. Use fender covers to avoid damaging painted
surfaces.
To avoid damage, unplug the wiring connectors
carefully whlle holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100'F (38"C)
betore loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
'1.
2.
3.
Drain the engine coolant (see page 10-6).
Remove the drive belt (see page 4-26).
Remove the intake manifold {see page 9-3).
Remove the air cleaner housing (see step 7 on page
5-2t.
5. Remove the water bypass hose (A).
Remove the exhaust manifold (see page 9-7
Remove the cam chain (see page 6-12).
6.
7.
).
8. Remove the engine wire harness connectors and
wire harness clamps from the cylinder head.
. Engine coolant temperature (ECT) sensor
conneclor. Camshaft position (Cl\4P) (top dead center (TDC))
sensor B connector. Camshaft posilion (CMP) sensor A connector
9. Remove the upper radiator hose (A) and heater
hose (B).
'10. Remove the harness holder (A)from the bracket,
then remove the connecting pipe mounting boh {B)
and brake booster vacuum line mounting bolts {C).
(cont'd)
1 1. Remove the water bvpass hose (D).
6-23

Cylinder Head
tJ.
Cylinder Head Removal (cont'd)
Remove the rocker arm assembly (see page 6-26).
Remove the cylinder head bolts. To prevent
warpage, unscrew the bolts in sequence 1/3 turn at
a time; repeat the sequence until all bolts are
loosened.
CYLINDER HEAD BOLTS LOOSENING SEQUENGE:
14. Remove the cylinder head.
6-24
VTC Actuator, Exhaust Camshaft\
Sprocket Replacement
Removal:
1. Remove the cam chain (see page 6-12).
2. Hold the camshaft with an open-end wrench, then
loosen the variable valve timing control (VTC)
actuator mounting bolt and exhaust camshaft
sprocket mounting bolt.
Remove the VTC actuator and exhaust camshaft
sprocket.
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Cylinder Head
'1.
2.
Rocker Arm Assembly Removal
Remove the cam chain (see page 6-12).
Loosen the rocker arm adjusting screws (A),
A
3. Remove the camshaft holder bolts. To Drevent
damaging the camshafts, unscrew the bolts two
turns at a time, in a crisscross pattern.
CAMSHAFT HOLDER BOLTS LOOSENING
SEOUENCE:
6-26
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4.Remove the cam chain guide B, camshaft holders,
and camshafts.
Insert the bolts (A) Into the rocker shaft holder, then
remove the rocker arm assembly (B).5.
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Valves, Springs, and Valve Seals Removal
Special Tools Bequired
Valve spring compressor attachment 07VAE-001010A
ldentify the valves and valve springs as they are
removed so that each item can be reinstalled in its
original position.
1. Remove the cylinder head (see page 6-23).
2. Using an appropriate-sized socket (A) and plastic
mallet {B), lightly tap the valve retainer to loosen
the valve keepers.
Install the spring compressor. Compress the spring,
and remove lhe valve keepers.
4. Installthe valve guide seal remover.
5.the valve seal.Remove
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6-31

Valve Guide Replacement
Special Tools Required. Valve guide driver, 5.5 mm 07742-0010100. Valve guide reamer, 5.5 mm 07HAH-PJ7o108
1.Inspect valve stem-to-guide clearance (see page 6-
32t.
As illustrated below, use a commercially available
air-impact valve guide driver (A) modified to fit the
diameter of the valve guides. In most cases, the
same procedure can be done using the special tool
and a conventional hammer.
10.8 mm{0.,|2 in.)
3. Select the proper replacement guides, and chill
lhem in the freezer section of a refriqerator for
about an hour.
4. Use a hot plate or oven to evenly heat the cylinder
head to 300'F (150"C). Monitor the temperature
with a cooking thermometer. Do not getthe head
hotterthan 300'F (150"C); excessive heat may
loosen the valve seats.
-_|Jfillr-.-4fi'11., -
tT
7.
Working from the camshaft side. use the driver and
an aar hammerto drive the guide about 2 mm (0.1
in.)towards the combustion chamber. This will
knock off some of the carbon and make removal
easier. Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
Turn lhe head over, and drive the guide out toward
the camshaft side of the head.
lf a valve guide won't move, drill it out with a I mm
(5/16 inch) bit. then try again. Drill guides only in
extreme cases;you could damage the cylinder
head if the guide breaks.
Remove the new guide(s) from the freezer, one at a
time, as vou need them.
(cont'd)
6-33

Engine Block
Crankshaft and Piston Removal
1. Remove the engine assembly (see page 5-2).
2. Remove the transmission (see page 13-4).
3. Remove the oil pan (see page 7-1 1).
4. Remove the oil pump {see page 8-9).
5. Remove the cylinder head (see page 6-23).
6. Remove the baffle plates.
7. Remove the 8 mm bolts.
E
7-12
8. Remove the bearing cap bolts. To prevent warpage,
unscrew the bolts in sequence 1/3 turn at a time:
repeat the sequence until all bolts are loosened.
Remove the lower block and bearings, Keep all
bearings in order.
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Cooling System
Radiator and Fans Replacement
1. Drain the engine coolant (see page 10-6).
2. Remove the front bumper {see page 20,85).
3. Remove the bulkhead.
4. Remove the upper radiator hose and lower radiator hose.
DRAIN PLUG
UPPER BADIATOR HOSE
BAOIATOA FANASSEMBLY
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O.RINGRADIATOR CAP
BADIATOB
LOWERCUSHION
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RADIATOR FANswtTcH24Nm{2.1t kgl m. 17lbl hl
LOWER FADIATORHOSE
RESERVETANK
A/C CONDENSERFAN ASSEMBLY
9.8 N m {1.0 kgf m,7.2 lbf ft)CONNECTORSRADIATOB FAN SWITCHCONNECTOB
5. Disconnect the fan motor connectors and radiator fan switch connector, then pull the radiator up and out.
6. Remove the fan shroud assemblies and other parts from the radiator.
7. Installthe radiator in the reverse order of removal. Make sure the upper and lower cushions are set securelV.
8. Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts.
9. Fill the radiator with engine coolant and bleed the air (see page 10-6).
10-10
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WC OilControl Solenoid Valve Removal/Test
1. Remove the WC oilcontrol solenoid valve (A).
NOTE: lnstall the valve in the reverse order of
removal with a new o-ring (B), then check these
tlems:
Clean and dry the VTC oil control solenoid valve
mating surface.
Coat the O-ring with engine oil.
Do not install the VTC oilcontrol solenoid valve
while wearing fibrous gloves,
Be careful not to contaminate the cylinder head
openrng.
Check the VTC oil control solenoid valve filter for
clogging. lf it is clogged, replace the VTC oil control
solenoid valve.
Check the clearance between the port (advance
side) and the valve. The clearance (A) should be at
least 2.8 mm (1/8 in.).
Connect the battery positive terminal to VTC oil
control solenoid valve 2P connector terminal No. 2.
VTC OIL CONTROL SOLENOIDVALVE 2P CONNECTOR
Terminal side oJmale terminals
Connect the battery negative terminal to VTC oil
control solenoid valve 2P connector terminal No. 1,
then make sure the valve (A) opens fully.
BATTERY
11-127